Spray gun system with elastic flow control valve

Abstract

Aspects of the present disclosure relate to a method that includes mounting a resilient flow control valve within a portion of a liquid passage formed in a spray gun system such that liquid can be contained by the resilient flow control valve without leakage. A wettable needle chamber may be coaxial with a portion of the fluid passageway. The present disclosure may also relate to a kit including a resilient flow control valve configured to sealingly engage with or directly adjacent to a portion of a nozzle liquid passage of a nozzle assembly.

Description

Background Art

[0001] Spray equipment is used in many processes including surface coating applications, combustion and chemical reaction control. Spray equipment can include a device that converts bulk liquid into a fine spray or mist of droplets. The size and shape of the spray equipment can depend on the desired application and / or delivery system. Applications over the years include delivering gaseous hydrocarbon feeds, dispensing chemical pesticides and applying protective or aesthetically pleasing surface coatings in fluidized catalytic cracking processes.

[0002] Spray equipment can be used, for example, in a vehicle repair body shop to apply liquid coating media such as primer, paint and / or varnish to vehicle parts. Spray equipment such as a spray gun can be made of a combination of metal and polymer materials, and includes a platform and a spray head assembly. The spray head assembly includes a nozzle for distributing liquid, one or more atomizing gas outlets for atomizing the liquid when the liquid leaves the nozzle, and two or more shaping gas outlets for shaping the atomized liquid into a desired spray pattern. The spray gun contains a series of internal passages that distribute gas from a gas supply manifold in the platform to the atomizing gas outlet and shaping gas outlet in the spray head assembly. Such spray guns are sometimes referred to as air atomization type, air spray type, air-assisted type or air impact type. Summary of the invention

[0003] In some designs, a manually operated valve such as a needle valve is used to control the flow of coating liquid through the spray gun (see, e.g. Figure 1 , Figure 2 and Figure 3 ). A needle (or valve stem) is positioned along the central axis of the nozzle and cuts off on the valve seat (nozzle sealing surface) near the liquid outlet. The needle / stem is typically connected to a trigger that is a means of actuation by hand by the user. When the trigger is pulled back by the user, the needle will slide away from the valve seat and allow liquid to flow through the channel outlet. When the trigger is released, a biasing mechanism (e.g., a spring) is used to push the needle back to its closed position in contact with the valve seat. Along the length of the needle, a seal (or packing) is used to isolate the liquid in the flow channel from the external area of ​​the spray gun.

[0004] These components found in the aforementioned spray gun systems are known to use tight manufacturing tolerances, significantly increase the cost of the spray gun, wear over time due to cycling, and require routine cleaning and maintenance by the user.

[0005] Aspects of the present disclosure may relate to an improved needle assembly. The improved needle assembly may include a first shaft segment having a first end. The first end is configured to be oriented toward a nozzle sealing surface of a spray gun system. The improved needle assembly may also include a second shaft segment having a second end opposite to the first end. The second shaft segment is configured to be assembled in a non-wettable needle chamber of the spray gun system. The second end is configured to be operably engaged with a component of the spray gun system, and the first end is configured to not contact the nozzle sealing surface to form a needle-nozzle seal. The improved needle assembly has a needle length dimension that is less than a length dimension of a needle passage of the spray gun system.

[0006] In at least one embodiment, the improved needle assembly can include a needle boss located between the first shaft segment and the second shaft segment. The needle boss is configured to engage with a biasing mechanism, a poppet valve, and / or a trigger.

[0007] In at least one embodiment, the needle boss is crimped.

[0008] In at least one embodiment, the first shaft segment has a length dimension that is smaller than a conventional needle used in a spray gun system.The first end is configured not to form a fluid-tight seal with the spray gun system.

[0009] In at least one embodiment, the second shaft segment is configured to form a slidable fluid-tight seal with the packing seal.

[0010] In at least one embodiment, the first shaft segment is configured to form a fluid-tight seal with a poppet valve.The poppet valve seals the needle chamber of the non-wettable needle chamber and engages with a trigger of the spray gun system.

[0011] In at least one embodiment, the poppet valve includes a through passage from the poppet valve flange end to the poppet valve distal end.

[0012] In at least one embodiment, the poppet valve is configured to contact a biasing mechanism in the needle chamber of the non-wettable needle chamber.

[0013] In at least one embodiment, the improved needle assembly includes a sealing structure disposed on the first end of the first shaft segment. The sealing structure is configured to form a fluid-tight seal with a portion of the needle passage to separate the needle passage into a wettable needle chamber and a non-wettable needle chamber.

[0014] In at least one embodiment, the needle boss is configured such that when the improved needle assembly is assembled into a spray gun platform and the sealing structure forms a fluid-tight seal with a portion of the needle passageway, the needle boss does not engage a trigger of the spray gun system.

[0015] In at least one embodiment, the second shaft segment is configured to engage the biasing mechanism.

[0016] Another aspect of the present disclosure relates to a kit. The kit may include a resilient flow control valve configured to sealingly engage within a portion of a nozzle liquid passage of a nozzle assembly or directly adjacent to the nozzle liquid passage. The nozzle assembly generally includes: a nozzle gas inlet and a nozzle gas outlet forming an atomizing gas passage therebetween; and a nozzle liquid inlet and a nozzle liquid outlet forming a nozzle liquid passage therebetween. The atomizing gas passage is configured to be removably coupled to a gas passage of a spray gun platform. The nozzle liquid passage is configured to form a fluid-tight seal with a needle of a spray gun platform at a needle-nozzle seal of the nozzle assembly.

[0017] In at least one embodiment, the kit can include a spray gun platform, which can be a conventional spray gun.The nozzle assembly can include a needle passageway coaxial with the overall nozzle fluid passageway.

[0018] In at least one embodiment, the nozzle assembly includes an attachment structure on an exterior surface that is configured to mate with a compatible attachment structure on a spray gun platform.

[0019] In at least one embodiment, an airbrush system includes an airbrush platform and a nozzle assembly.The airbrush system includes a needle passage configured to allow a conventional needle to pass through both the airbrush platform and the nozzle assembly.

[0020] In at least one embodiment, a portion of the nozzle fluid passage is coaxial with the needle passage.

[0021] In at least one embodiment, the entire fluid passageway is coaxial with the needle passageway.

[0022] In at least one embodiment, the needle passage includes a wettable needle chamber and a non-wettable needle chamber. The secondary opening leads to the wettable needle chamber. In at least one embodiment, a packing seal separates the wettable needle chamber from the non-wettable needle chamber.

[0023] In at least one embodiment, when the nozzle assembly is assembled with the spray gun platform and operating in the first mode, the differential pressure across the elastomeric flow control valve is less than the opening pressure of the elastomeric flow control valve and results in a closed configuration.

[0024] In at least one embodiment, in the second mode, gas flow from the spray gun system including the spray gun platform and the nozzle assembly causes a differential pressure across the elastomeric flow control valve to be at least an opening pressure of the elastomeric flow control valve and thereby causes the elastomeric flow control valve to change to an open configuration.

[0025] In at least one embodiment, the resilient flow control valve includes a slit that is capable of forming an opening in the open configuration.

[0026] In at least one embodiment, the non-wettable needle chamber includes a first needle chamber and a second needle chamber.

[0027] In at least one embodiment, the kit includes a sealing structure to seal the secondary opening of the spray gun platform or nozzle assembly.

[0028] In at least one embodiment, the kit includes a sealing structure to fluidly separate the wettable needle chamber from the non-wettable needle chamber.

[0029] In at least one embodiment, the nozzle assembly is a nozzle cartridge wherein a nozzle liquid passage is formed between a nozzle liquid inlet and a nozzle liquid outlet, and the wettable needle chamber is formed by a portion of the nozzle liquid passage between the nozzle liquid outlet and the secondary opening.

[0030] In at least one embodiment, the airbrush platform includes a non-wettable needle chamber formed therein. In at least one embodiment, the kit can include a poppet valve configured to: (1) not allow the needle to pass through, (2) slidably seal the non-wettable needle chamber, and (3) engage a trigger of the airbrush platform.

[0031] In at least one embodiment, a kit can include the improved needle assembly described herein.

[0032] In at least one embodiment, the poppet valve can have a poppet valve inner diameter and a poppet valve outer seal.The improved needle assembly can be configured to form a slidable fluid-tight seal with the poppet valve inner diameter.

[0033] In at least one embodiment, the resilient flow control valve includes a flange configured to form a fluid-tight seal with a rim of an attachment structure proximate the nozzle assembly.

[0034] In at least one embodiment, the kit can include a frame structure between the elastomeric flow control valve and the nozzle assembly. The frame structure can be integrally formed with the elastomeric flow control valve.

[0035] In at least one embodiment, the kit may include a liner assembly including a liner tube and a liner liquid inlet. The liner assembly is configured to receive liquid from the liner liquid inlet through the distal end of the liner tube. The elastic flow control valve is configured to form a fluid-tight seal with the liner assembly.

[0036] In at least one embodiment, the elastomeric flow control valve is formed as a single assembly with the liner assembly.

[0037] In at least one embodiment, the liner is configured to pass through and conform to a portion of: (1) a liquid passageway of a spray gun platform, and / or (2) a nozzle liquid passageway of a nozzle assembly.

[0038] In at least one embodiment, an elastic flow control valve is attached to the distal end.

[0039] Aspects of the present disclosure are directed to a method (e.g., a method of modifying a spray gun system and / or a nozzle assembly) comprising: installing an elastomeric flow control valve within a portion of a liquid passage formed in the spray gun system such that liquid can be contained by the elastomeric flow control valve without leaking through a liquid outlet, a nozzle liquid outlet, and / or a secondary opening. A wettable needle chamber (of the nozzle assembly) is coaxial with the portion of the liquid passage.

[0040] In at least one embodiment, the method may include: sealing a secondary opening of a needle passage formed in a spray gun system including a spray gun platform and a nozzle assembly with a sealing structure. In at least one embodiment, the needle passage is configured to allow a conventional needle to pass through both the spray gun platform and the nozzle assembly. In at least one embodiment, the seal forms a wettable needle chamber and a non-wettable needle chamber from the needle passage. In at least one embodiment, sealing the secondary opening does not use a conventional needle.

[0041] In at least one embodiment, sealing the secondary opening of the needle passage comprises inserting a liner assembly into the liquid inlet, through a portion of the liquid passage and toward the liquid outlet. In at least one embodiment, another portion of the liquid passage is coaxial with the wettable needle chamber. In at least one embodiment, the liner assembly comprises a liner tube and a liner liquid inlet. The liner assembly is configured to accommodate liquid from the liner liquid inlet through a distal end of the liner tube. In at least one embodiment, the distal end of the liner tube has an elastic flow control valve mounted thereon. In at least one embodiment, installing the elastic flow control valve comprises inserting the liner tube through the liquid passage.

[0042] In at least one embodiment, sealing the secondary opening includes inserting a sealing structure into the secondary opening and at least partially into the wettable needle chamber.

[0043] In at least one embodiment, the sealing structure is configured to attach to the body of the spray gun platform or nozzle barrel and fill the secondary opening.

[0044] In at least one embodiment, the sealing structure is configured to fill a majority of the wettable needle chamber.

[0045] In at least one embodiment, sealing the secondary opening includes forming a wall over the secondary opening.

[0046] In at least one embodiment, installing the elastomeric flow control valve includes positioning the elastomeric flow control valve such that when the spray gun system is operated in the first mode, a differential pressure across the elastomeric flow control valve is less than an opening pressure of the elastomeric flow control valve and results in a closed configuration.

[0047] In at least one embodiment, in the second mode, gas flow from the spray gun system including the spray gun platform and the nozzle assembly causes a differential pressure across the elastomeric flow control valve to be at least an opening pressure of the elastomeric flow control valve and thereby causes the elastomeric flow control valve to change to an open configuration.

[0048] In at least one embodiment, the method may further include removing the nozzle assembly from the spray gun platform prior to sealing the secondary opening.

[0049] In at least one embodiment, the nozzle assembly is a nozzle cartridge removably coupled to a spray gun platform. The secondary opening is located in the nozzle cartridge. In at least one embodiment, sealing the secondary opening includes: sealing a wettable needle chamber of the nozzle cartridge, and installing the elastic flow control valve includes: installing the elastic flow control valve in a nozzle liquid passage of the nozzle cartridge to form a valved nozzle cartridge. In at least one embodiment, the method may include: installing the valved nozzle cartridge onto the spray gun platform.

[0050] In at least one embodiment, the nozzle assembly is a spray gun nozzle body having a nozzle liquid passageway fully aligned along the spray axis, and on a spray gun platform, the liquid inlet is configured to be coupled to the liquid outlet. The secondary opening is located in the spray gun platform. In at least one embodiment, installing the elastic flow control valve includes: installing the elastic flow control valve in the nozzle liquid passageway of the spray gun nozzle body to form a valved fluid nozzle. In at least one embodiment, the method may include: installing the valved fluid nozzle on the spray gun platform.

[0051] In at least one embodiment, the method can include receiving a spray gun system, the spray gun system can include a spray gun platform, the spray gun platform including a liquid inlet, a secondary opening, and a liquid outlet forming a liquid passage therebetween.

[0052] In at least one embodiment, the method can include removing the conventional needle from the needle passage.

[0053] In at least one embodiment, the method may include installing a modified needle assembly. The modified needle assembly does not form a needle-nozzle seal with the spray gun system. In at least one embodiment, when installed, the first end of the modified needle assembly is at least 0.5 mm away from the elastic flow control valve, or the size of the elastic flow control valve.

[0054] In at least one embodiment, the portion of the sealed needle pathway does not include a conventional needle.

[0055] In at least one embodiment, the method may include: attaching pressurized air to the gas inlet of the spray gun system. In at least one embodiment, the flow of liquid through the liquid outlet is stopped by the operation of the elastic flow control valve rather than the needle valve. Therefore, a needle-nozzle seal is not formed.

[0056] Additional aspects of the present disclosure relate to a method. The method includes removing or modifying a conventional needle of a spray gun system so that the needle is no longer able to form a needle-nozzle seal near a liquid outlet. In at least one embodiment, the method includes installing an elastic flow control valve in a portion of a liquid passage of the spray gun system.

[0057] In at least one embodiment, a seal is mounted in the needle passage proximate the secondary opening. BRIEF DESCRIPTION OF THE DRAWINGS

[0058] To easily identify the discussion of any particular element or act, the most significant digit(s) in a reference number refers to the figure numeral that first introduces that element.

[0059] Figure 1 A cross-sectional side view of a prior art spray gun system is illustrated according to one embodiment.

[0060] Figure 2 Illustrated Figure 1 A cross-sectional side view of a portion of a showerhead assembly in which selected portions have been removed to more clearly illustrate certain features.

[0061] Figure 3 A cross-sectional side view of a prior art spray gun system is illustrated according to one embodiment.

[0062] Figure 4 A block diagram of a spray gun system 400 having a flexible flow control valve is illustrated according to one embodiment.

[0063] Figure 5A Illustrated is a cross-sectional view of an elastic flow control valve 510 in a closed configuration according to one embodiment.

[0064] Figure 5B Illustrated is a cross-sectional view of an elastic flow control valve 510 in an open configuration according to one embodiment.

[0065] Figure 6 A flow chart illustrating a method according to one embodiment is shown.

[0066] Figure 7 A cross section of a prior art spray gun system with a sealing structure installed according to one embodiment is illustrated.

[0067] Figure 8 A cross-sectional perspective view of an improved spray gun system according to one embodiment is illustrated.

[0068] Fig. 9 A cross-sectional perspective view of an improved spray gun system showing a sealing structure is illustrated according to one embodiment.

[0069] Fig.10 A cross-sectional perspective view of an improved spray gun system according to one embodiment is illustrated.

[0070] Fig.11 A cross-sectional perspective view of an improved spray gun system according to one embodiment is illustrated.

[0071] Fig. 12A A perspective view of a nozzle assembly according to one embodiment is illustrated.

[0072] Fig. 12B An example of a method according to one embodiment of the present invention is shown in FIG. Fig. 12A A cross-sectional side view of a nozzle assembly.

[0073] Fig.13 A cross-sectional perspective view of a nozzle assembly according to one embodiment is illustrated.

[0074] Fig.14A A perspective view of a nozzle assembly according to one embodiment is illustrated.

[0075] Fig. 14B An example is given according to an embodiment Fig.14A Cross-sectional view of the nozzle assembly in FIG.

[0076] Fig.15A A nozzle assembly having a flexible flow control valve according to one embodiment is illustrated.

[0077] Fig. 15B An example of a nozzle assembly according to one embodiment is shown. Fig.15A Flexible flow control valve.

[0078] Fig.16 An improved needle assembly according to one embodiment is illustrated.

[0079] Fig.17 An improved needle assembly according to one embodiment is illustrated. DETAILED DESCRIPTION

[0080] The spray equipment of the present disclosure can allow a user to generate a spray of atomized liquid for a variety of coating applications. Such coating applications can be performed to improve the appearance of a substrate, impart corrosion resistance to a substrate, impart wear resistance to a substrate, improve moisture resistance to a substrate, and improve cleanability of a substrate.

[0081] Aspects of the present disclosure relate to spray equipment that is improved to control the delivery of liquid using an elastic flow control valve within a liquid passage formed therein, without using a manually operated valve, such as a needle valve actuated by a trigger or actuator. The elastic portion of the elastic flow control valve has the ability to adjust its opening behavior based on changes in pressure differential, and possesses inherent elasticity to remain in a normally closed configuration once a predetermined pressure differential is reached.

[0082] Another aspect of the present disclosure relates to a method for replacing a conventional needle with an elastic flow control valve for use in a spray gun system. The needle passage of the spray gun system can be sealed and a non-wettable needle chamber and a wettable needle chamber can be formed. The sealing can be performed at least in part based on the position of a pre-existing packing seal.

[0083] The resilient portion used in the present disclosure is preferably made of a resilient, elastic and flexible material. Such materials are selected to give the valve the ability to recover its original shape after being deformed (i.e., bent, stretched, compressed, etc.) in use. These materials may include, but are not limited to, natural and synthetic rubbers (EPDM, silicone rubber, etc.), thermoplastic polymers (LDPE, polypropylene, etc.), elastomers, thermosetting polymers and thermoplastic elastomers (including thermoplastic vulcanizates, thermoplastic polyurethanes, thermoplastic copolyesters, thermoplastic polyamides, etc.).

[0084] The shape and / or deformation of the elastic portion is affected by the surrounding fluid. Therefore, it is important to describe how this process can occur. The elastic portion can be understood as having two "sides" and describing their orientation relative to the fluid flow. The upstream side (e.g., Figure 5A The upstream side 528a in the embodiment faces the liquid inlet and has a fluid pressure (P1) acting thereon from the liquid. The downstream side (e.g., Figure 5A The downstream side 528b in the valve faces the liquid outlet and also has a fluid pressure (P2) acting on it. These fluid pressures may be independent of any internal or residual stresses designed into the valve itself. It should be understood that the shape of the valve may be affected by the difference in fluid pressure between its upstream and downstream sides. This gives rise to the concept of differential pressure across the valve. A positive pressure differential indicates that the average upstream fluid pressure is greater than the average downstream fluid pressure. A negative pressure differential indicates that the average upstream fluid pressure is less than the average downstream pressure.

[0085] In the first mode, the resilient portion will be able to seal / close in a closed configuration so that liquid (if present on the upstream side 528a) does not flow therethrough. In the first mode, the resilient portion may be configured to remain closed. The resilient portion may be inherently self-sealing, or the sealing may be achieved / assisted by a specified pressure differential.

[0086] By adjusting the fluid conditions around the elastic portion, thereby changing the pressure differential, the valve can be deformed from its closed configuration (in a first operating mode of the spray gun system) to an open configuration (e.g., in a Figure 5B The second operating mode of the spray gun system illustrated in the drawings) allows the opening to overcome the opening pressure and allow liquid to flow through the valve. The resilient portion may include an attachment structure configured to seal against a component of the resilient flow control valve and / or a nozzle assembly wall.

[0087] The disclosed spray equipment can reduce the number of parts, complexity, cost, eliminate the need for precision machined needles and seals used in spray equipment, achieve a nozzle design that can be more easily removed from the spray equipment, and achieve a nozzle design that keeps the paint reservoir sealed from the atmosphere even when disconnected from the spray equipment. This approach is different in that it does not require a precision machined needle, precision machined valve seat, packing seals, nor a needle spring as is typically found in prior art spray equipment.

[0088] Additional aspects of the present disclosure may involve positioning the elastomeric flow control valve adjacent to the liquid outlet (eg, within 5 cm).Such a configuration may further reduce the amount of liquid retained by the nozzle assembly and improve the cleanliness of the nozzle assembly.

[0089] Although the spray equipment of the present disclosure is designed to address some of the shortcomings associated with current manual, handheld spray guns as described above, it should be understood that the spray equipment disclosed herein may be readily configured for other devices and / or applications for atomizing liquids without departing from the scope of the present disclosure.

[0090] Figure 1 and Figure 2 A spray gun system 100 is illustrated. The spray gun system 100 includes a spray gun platform 102 and a nozzle assembly 104.

[0091] The spray gun platform 102 includes a gas inlet 106 configured to couple with a gas source (not shown). The spray gun platform 102 may also include a grip portion 112, a trigger 114, and a liquid inlet 116 for connecting to a compatible liquid reservoir system (not shown).

[0092] In at least one embodiment, a liquid passage 144 can be formed within the spray gun platform 102 between the liquid inlet 116 and the liquid outlet 122. The liquid passage 144 can also include a liquid chamber 146. If the nozzle assembly 104 is removed, the liquid passage 144 can be formed between the liquid inlet 116 and an opening adjacent to an attachment structure 148 where the spray gun platform 102 can be attached to the nozzle assembly 104.

[0093] In at least one embodiment, the liquid passage 144 (e.g., the liquid chamber 146) can share portions with the needle passage 160 (e.g., portions of the needle chamber 156 that can be wetted). The needle passage 160 is configured to hold a conventional needle 138 used in operation of the spray gun system 100. The needle passage 160 can be configured to allow the conventional needle 138 to axially pass through the spray gun platform 102 and / or the nozzle assembly 104. In at least one embodiment, the needle passage 160 is formed in portions of the nozzle assembly 104 and the spray gun platform 102. The needle passage 160 can have a length dimension 168 that is approximately the size of the conventional needle 138.

[0094] Needle passage 160 can include a non-wettable needle chamber 158 and a wettable needle chamber 156 separated from the non-wettable needle chamber 158 via a secondary opening 154 and / or a packing seal 150. In at least one embodiment, secondary opening 154 leads to and separates wettable needle chamber 156 from non-wettable needle chamber 158.

[0095] In at least one embodiment, the wettable needle chamber 156 is a portion of the needle passage 160 that is configured to contact the liquid. Both the wettable needle chamber 156 and the non-wettable needle chamber 158 can each also include one or more chambers. In at least one embodiment, the needle passage 160 can be oriented parallel or coaxially with the spray axis 124.

[0096] In at least one embodiment, the conventional needle 138 has a needle protrusion 140 that is configured to engage with the trigger-valve engagement interface 152 and the biasing mechanism 142. The biasing mechanism 142 can further abut against an adjustment knob 164. The adjustment knob 164 can limit the movement of the conventional needle 138 along the spray axis 124 in a direction opposite to the needle tip 136. In at least one embodiment, the conventional needle 138 can be axially disposed within the needle passage 160 so as to be capable of translational movement. In at least one embodiment, a packing seal 150 can be used to slidably seal the conventional needle 138 against the secondary opening 154. The packing seal 150 can separate the wettable needle chamber 156 from the non-wettable needle chamber 158. A fluid-tight seal between the spray gun platform 102 and the nozzle liquid passage 202 can be formed by the packing seal 150. Over time, the packing seal 150 can wear and thus can be replaced.

[0097] The spray gun platform 102 can have gas passages (eg, shaping gas passage 110 and atomizing gas passage 108 ) formed therein and fluidly coupled to the gas inlet 106 at one end. At the opposite end, the gas passages can be releasably coupled to gas passages within the nozzle assembly 104 .

[0098] In at least one embodiment, the nozzle assembly 104 can be a nozzle cartridge (which is further described herein).

[0099] As shown, the nozzle assembly 104 can be coaxial or parallel to the spray axis 124. For example, the nozzle assembly 104 can include a spray gun nozzle body 120 having a nozzle gas inlet 218 and a nozzle gas outlet (e.g., annular opening 204) to form an atomizing gas passage 210 therebetween. The spray gun nozzle body 120 has a nozzle liquid passage 202 aligned along the spray axis 124 and a nozzle liquid inlet 216 configured to be coupled to a liquid outlet (e.g., a liquid chamber) on the spray gun platform 102. As shown, the secondary opening 154 is located in the spray gun platform 102. In at least one embodiment, the secondary opening 154 can be juxtaposed with the packing seal 150 and can separate the wettable needle chamber 156 from the non-wettable needle chamber 158.

[0100] The atomizing gas passage 210 is configured to be removably coupled to the atomizing gas passage 108 of the spray gun platform 102 .

[0101] The nozzle assembly 104 may include a spray gun nozzle body 120, a retaining ring 118, and an air cap 126. The air cap 126 may include an annular opening 204 and two or more diametrically opposed air horns 128 containing horn passages 130 terminating at horn outlets 132. Although the air horns 128 and air cap 126 are used to describe the configuration, various other gases and / or carrier fluids other than air may be used.

[0102] The spray gun nozzle body 120 may include a liquid outlet 122 sealed with a needle tip 136 that interacts with a nozzle sealing surface 206 of a nozzle wall 208 to form a needle-nozzle seal 162. The spray gun nozzle body 120 may also include a nozzle liquid inlet 216 and a liquid outlet 122 that form a nozzle liquid passage therebetween. The nozzle liquid passage 202 may be configured to (1) be removably coupled to a liquid passage 144 of a spray gun platform 102 at a second end, and (2) form a needle-nozzle seal 162 with a conventional needle 138 of the spray gun platform 102 at a first end opposite the second end.

[0103] The spray gun nozzle body 120 may also include an attachment structure 214 (disposed on an outer surface) for attaching to the attachment structure 148 on the spray gun platform 102 and forming a releasable connection.

[0104] To operate the spray gun system 100, the user's hand depresses the trigger 114, which actuates the gas valve 134 via the poppet valve 166 and also translates the conventional needle 138 (via the needle protrusion 140 and the biasing mechanism 142) along the spray axis 124 away from the nozzle sealing surface 206. Actuation of the gas valve 134 allows gas to flow from the gas inlet 106, through the gas valve 134, and into the shaping gas passage 110 and the atomizing gas passage 108.

[0105] In operation, gas from the atomizing gas passage 210 can flow along the exterior of the nozzle wall 208 and through the annular opening 204 (i.e., forming a gas outlet), thereby creating a venturi effect that draws liquid from the liquid reservoir system through the liquid inlet 116 and the nozzle liquid passage 202 until the liquid exits the spray gun nozzle body 120 at the liquid outlet 122, where the gas atomizes the liquid at the mixing zone 212. In some embodiments, the liquid reservoir system can benefit from gravity and / or pressure assistance. For example, the liquid reservoir system can be pressure-assisted, which can allow for the handling of viscous liquids.

[0106] The mixing zone 212 is where the gas flow from the atomizing gas passage 210 exiting the annular opening 204 merges, interacts, intersects, and / or atomizes the liquid flow from the nozzle liquid passage 202 exiting the liquid outlet 122. The gas may exit the horn passage 130 at the horn outlet 132 to shape the atomized liquid, thereby producing an approximately elliptical spray pattern.

[0107] When the trigger 114 is released, a biasing mechanism (such as a spring) may bias the conventional needle 138 against the nozzle sealing surface 206 to a closed position (thereby forming the needle-nozzle seal 162), which shuts off the flow of liquid.

[0108] In at least one embodiment, the spray gun system 100 can include a spray gun platform 102 having both a nozzle liquid passage 202 and an atomizing gas passage 210 formed therein. Thus, to clean the spray gun system 100, the gas cap 126 and the spray gun nozzle body 120 are removed.

[0109] Figure 3 A spray gun platform 300 is illustrated which is similar to the spray gun platform 102 except that the spray gun platform 300 may use a poppet valve 302 (coaxial with a conventional needle 138). Figure 1 A stacked configuration between the poppet valve 166 and the conventional needle 310 is illustrated.) In at least one embodiment, the poppet valve 302 can regulate the flow of gas, while the conventional needle 310 can regulate the flow of liquid.

[0110] The non-wettable needle chamber 330 may include a needle chamber 304 (front) and a needle chamber 308 (back). The needle chamber 308 may be separated from the needle chamber 304 via an air gap.

[0111] Conventional needle 310 may include shaft segment 322 and needle protrusion 306, which is configured to engage both poppet valve 302 (i.e., at poppet flange end 316) and needle biasing mechanism 326. Conventional needle 310 may also include needle tip 334, which is configured to engage a nozzle sealing surface on a corresponding nozzle assembly (not shown). Shaft segment 322 may have dimension 320.

[0112] The poppet valve 302 may include a poppet valve flange end 316 and a poppet valve distal end 312. A through passage 328 may be formed within the body of the poppet valve 302 from the poppet valve flange end 316 to the poppet valve distal end 312. The conventional needle 310 may pass through the through passage 328 such that the poppet valve 302 surrounds the conventional needle 310.

[0113] In at least one embodiment, the poppet flange end 316 is configured to engage the needle protrusion 306 and the poppet biasing mechanism 324. The adjustment knob 336 is configured to provide a backstop to the needle biasing mechanism 326 and optionally to the poppet biasing mechanism 324 so that both the conventional needle 310 and the poppet valve 302 are biased toward the needle tip 334. The trigger 314 can engage the poppet distal end 312 at the trigger engagement region 318 so that gas is exhausted when the trigger 314 is actuated, and the trigger 314 is configured to translate the conventional needle 310 along the spray axis 332 in response to actuation.

[0114] When combined with a compatible nozzle assembly (not shown), the needle tip 334 can form a needle-nozzle seal with the nozzle wall in a first mode in which no liquid (when present in the liquid passage) is expelled, and the needle-nozzle seal can be broken in response to a second mode in which the poppet valve 302 is opened. In at least one embodiment, in a nozzle cartridge configuration, the nozzle assembly can be coupled to a liquid reservoir system and the liquid passage is not directed through the spray gun platform 300. In at least one embodiment, the nozzle assembly can be constructed similarly to the nozzle assembly 104, in which the liquid passage is formed within the spray gun platform 300.

[0115] Figure 4A functional block diagram of an assembled spray gun system 400 according to aspects of the present disclosure is illustrated. The spray gun system 400 may include a spray gun platform 402, a nozzle assembly 404, a liquid reservoir system 406 having a liquid reservoir outlet 408 and containing a liquid, and a gas source 424 having a gas 422. The liquid reservoir system 406 may include any suitable container, reservoir, or housing that can be attached directly or indirectly (e.g., via a conduit, hose, aerosol can, etc.) to a liquid inlet 414 of the nozzle assembly 404. In at least one embodiment, the liquid inlet 414 refers to a functional inlet that can be paired with the liquid reservoir outlet 408 and can be located inside the body of the nozzle assembly 404. In at least one embodiment, the spray gun platform 402, the nozzle assembly 404, and the liquid reservoir system 406 (including its liquid reservoir components) can be referred to as spray gun components that are configured to be attached to the spray gun platform 402.

[0116] The liquid reservoir system 406 including the liquid reservoir outlet 408 can be reusable or disposable and can be pre-filled with liquid or can be filled on site. The liquid reservoir system 406 can optionally have a removable cover portion to assist in opening and closing the container. In at least one embodiment, the liquid reservoir system 406 can include a liquid reservoir component, such as a gravity-fed liquid reservoir system, which includes a cover, an adapter, or a portion thereof. In at least one embodiment, the liquid reservoir outlet 408 can flow into the liquid inlet 414 in the spray gun system 400 and flow out of the liquid outlet 416. The liquid inlet 414 and the liquid outlet 416 can be formed by openings in the various components of the spray gun system 400. The liquid inlet 414 and the liquid outlet 416 can be connected via a liquid passage 412.

[0117] The gas source 424 can be fluidly isolated from the atmosphere (i.e., a closed vessel) or contain a fluid inlet to allow for the intake of gas 422 from the surrounding environment (i.e., an air compressor). In at least one embodiment, the gas 422 from the gas source 424 can flow into the nozzle gas inlet 426 and out of the spray gun system 400 via the gas outlet 430. The nozzle gas inlet 426 and the gas outlet 430 can be connected via a gas passage 428.

[0118] In some embodiments, at least one of the gas source 424 and the liquid reservoir system 406 is pressurized. In some embodiments, the gas source 424 is pressurized. In some embodiments, the liquid reservoir system 406 is not pressurized. In other embodiments, the liquid reservoir system 406 is not pressurized by means other than hydrostatic pressure (e.g., the liquid reservoir system 406 is vertically positioned above the nozzle assembly 404 in a gravity-fed configuration).

[0119] In at least one embodiment, the spray gun system 400 can have a liquid reservoir system 406 fluidly connected to a flexible flow control valve 418a. Figure 4 As depicted, the flexible flow control valve may be positioned at a variety of locations along the liquid flow path from the liquid reservoir system 406 to the mixing zone 410 (e.g., 418a, 418b, 418c all refer to potential locations for the flexible flow control valve). The term flexible flow control valve 418a may be used interchangeably with flexible flow control valve 418b and flexible flow control valve 418c.

[0120] In at least one embodiment, the elastomeric flow control valve 418a can be positioned so that a sufficient pressure differential can be generated and controlled at that location during operation of the spray gun system 400 (e.g., sufficient to change the elastomeric flow control valve 418a to an open configuration). In at least one embodiment, the elastomeric flow control valve 418a is located within the liquid passage 412 of the nozzle assembly 404. The location of the elastomeric flow control valve 418a within the liquid passage 412 can depend on several factors, including the size and shape of both the valve and the passage, the desire to have an expansion chamber within the liquid passage, and any considerations regarding residual liquid present within the liquid passage when the elastomeric flow control valve 418a is closed. In at least one embodiment, the elastomeric flow control valve 418a can be placed in the middle of the liquid passage 412. In at least one embodiment, the elastomeric flow control valve 418a is located at the liquid outlet of the liquid passage 412 such that the outlet of the elastomeric flow control valve 418a is adjacent to the mixing zone 410.

[0121] In another embodiment, the elastomeric flow control valve 418c is located within the liquid reservoir system 406, such as in the liquid reservoir outlet 408 or a cap of the liquid reservoir system 406. In at least one embodiment, the elastomeric flow control valve 418b can be located within a conduit connecting the liquid reservoir system 406 to the nozzle assembly 404. From the examples given, it should be understood that a variety of locations are acceptable for the placement of the elastomeric flow control valve.

[0122] In at least one embodiment, two or more elastic flow control valves can be used in the same spray gun system 400. The use of more than one elastic flow control valve can provide backup in the event that another elastic flow control valve fails. Additionally, the use of two or more elastic flow control valves can allow the separable components to remain sealed to the air when disconnected. In at least one embodiment, the elastic flow control valve 418a is located at the liquid inlet 414 to the nozzle assembly 404, and another elastic flow control valve 418c is located in the lid of the liquid reservoir system. In at least one embodiment, the liquid inlet 414 may include a portion of the needle passage that can be sealed by the sealing structure 432. When the liquid reservoir system is disconnected from the nozzle assembly, the two components can remain sealed to the atmosphere.

[0123] The spray gun system 400 may include a gas valve 420 placed between a gas source 424 and a nozzle gas passage 428 to manage gas flow within the spray gun system 400. Exemplary gas valves 420 include poppet valves, ball valves, pinch valves, diaphragm valves, and needle valves commonly used in pneumatic applications. In at least one embodiment, the gas valve 420 may be placed within the spray gun system 400 such that the gas valve (indirectly) affects the degree of opening of at least one elastic flow control valve 418a. The indirect fluid communication path may extend across distinct channels (i.e., nozzle gas passage 428 to mixing zone 410 to liquid passage 412), across distinct fluids (i.e., pressure transferred between gas and liquid), or also across (deformable) partitioned separation channels.

[0124] The operation of the spray gun system 400 of the present application can be described by a series of events. In a first mode, the spray gun system 400 can contain liquid in the liquid reservoir system 406 and contain gas in the gas source 424. In this first mode, both the gas valve 420 and the elastic flow control valve 418a are in a closed position. Since both valves are closed, no gas or liquid flows through the spray gun system 400.

[0125] In the first mode, the gas valve 420 may be opened, which causes gas to flow from the gas source 424 through the gas valve 420. The flow of gas in the system changes the differential pressure across the flexible flow control valve 418a via the fluid coupling mechanism previously described. In the first mode, even if the gas is flowing, the differential pressure may not be sufficient to change the flexible flow control valve 418a from the closed configuration. In the second mode, under certain gas flow conditions, a predefined opening differential pressure of the flexible flow control valve 418a may be reached, thereby causing the flexible flow control valve 418a to change to an open configuration, thereby enabling liquid to pass through the liquid passage 412 (if an optional liquid is present). When both the gas and the liquid pass through their respective channels, the two fluids are directed to the mixing zone 410.

[0126] Atomization and spray formation processes may occur in the second state within the mixing zone 410. The atomization and spray formation processes may result in the generation of a spray comprising a mixture of at least two fluids (gas 422 and liquid), wherein the liquid has been atomized into small droplets from its initial bulk fluid state.

[0127] When it is desired to reduce or stop the spray emitted from the spray gun system 400, the gas valve 420 can be partially or completely closed. By closing the gas valve 420 (e.g., by a user interacting with an actuator), the flow of gas through the spray gun system 400 can be stopped, and the differential pressure across the flexible flow control valve 418a can be reduced. When the specified closing differential pressure of the flexible flow control valve 418a is reached, the flexible flow control valve 418a can seal itself and stop the flow of liquid through the liquid passage 412. This closing process returns the spray gun system 400 to the first mode.

[0128] Figure 5A and Figure 5B A cross-sectional view of a flexible flow control valve 510 is illustrated. Figure 5A The flexible flow control valve 510 is illustrated in a first mode, and Figure 5B The elastic flow control valve 510 is illustrated in the second mode.

[0129] The elastic flow control valve 510 is known in the art and is referred to in a variety of ways, including elastic valves, elastic closure members, discharge valve members, deformable outlet valves, dispensing closures, valve-controlled dispensing closures, elastomeric valves, double slit valves, and duckbill valves (not all of which are exhaustive). Examples of such valves may include, but are not limited to, EP3,280,652B1, US1,739,871, US5,676,289, and US6,053,194. Applications of such valves include, for example, food and beverage containers, powder, lotion, and soap dispensers, and manual pump spray bottles.

[0130] In at least one embodiment, the elastomeric flow control valve 510 includes at least a resilient portion 504, and optionally a frame structure 506 and / or a support portion 502. The components of the elastomeric flow control valve 510 may be formed from separate and distinct materials, each with their own properties.

[0131] The frame structure 506 may have a structure configured to be paired with the retaining structure of the nozzle assembly. The frame structure 506 may be relatively more rigid (e.g., as measured using the Shore A hardness test method) than the elastic portion 504. For example, the frame structure 506 may be rigid, while the elastic portion 504 is elastomeric. The frame structure 506 may be configured to be combined with both the elastic portion 504 and the support portion 502. The frame structure 506 may include various attachment features that facilitate mechanical engagement with other components of the nozzle assembly or the elastic flow control valve 510. For example, the frame structure 506 may include barbs 518 to fix the elastic portion 504 via the support portion 502. The frame structure 506 may have a sealing surface 530 that is configured to form a fluid-tight seal with a complementary sealing surface in the liquid passage.

[0132] In at least one embodiment, the frame structure 506 can be annular so that each portion of the frame structure 506 is equidistant from the center of the opening 514. By having the frame structure 506, the edge of the elastic portion 504 can be anchored within the liquid passage, and the position of the elastic portion 504 can be maintained at any differential pressure. In addition, by separating the frame structure 506 from the elastic portion 504, the nozzle assembly can be customized according to the application by replacing the elastic flow control valve 510.

[0133] In at least one embodiment, the support portion 502 can be a component that acts as an intermediary between the elastic portion 504 and the frame structure 506. Figure 5A As shown, the support portion 502 is also configured to direct liquid toward the resilient portion 504 .

[0134] In at least one embodiment, the support portion 502 can be formed of a more rigid material than the resilient portion 504. In at least one embodiment, the support portion 502 can be configured to facilitate the bonding of the resilient portion 504 to the frame structure 506 and / or dissipate forces from the resilient portion 504. The support portion 502 can have features that assist in the retention and / or force dissipation of the resilient portion 504 relative to the frame structure 506. For example, the support portion 502 can include a complementary feature configured to mate with the barb 518 on the frame structure, and another complementary feature configured to mate with the attachment structure 520 on the resilient portion 504. In at least one embodiment, the support portion 502 or the frame structure 506 can have a rim 522 on a distal surface opposite the direction of the opening 514. In at least one embodiment, the rim 522 can have an outer diameter (e.g., measured in a plane orthogonal to the resilient flow control valve axis 512) that is larger than the outer diameter of the frame structure 506.

[0135] The elastic part can be designed to have a predefined opening differential pressure (e.g., opening pressure), which means when the valve deformation changes from the first mode to the second mode. The change in the opening degree or the opening cross-sectional area of ​​the elastic part can be further controlled by the magnitude of the differential pressure. This provides a certain degree of flow control, because the elastic flow control valve has many possible deformable states between the closed configuration and the open configuration. Another important feature of the elastic part is that the elastic part can return to the first mode when the differential pressure stimulus is removed. The closing differential pressure can be designed into the valve or as a characteristic of the valve, which describes when the valve will be changed back to the first mode from the second mode. In at least one embodiment, various aspects of the elastic part can be responsive to the differential pressure across the elastic part 504 to distribute liquid.

[0136] The elastic portion 504 may have a self-sealing opening 514 formed by one or more slits 524 therein. When in a closed configuration, one or more slits 524 may touch each other and form a fluid-tight seal. One or more slits 524 may be a feature that allows the elastic portion 504 to form an opening 514 when the elastic portion 504 is in an open configuration and in response to an opening pressure. In at least one embodiment, one or more slits 524 may be horizontal, vertical, combined, or even cross and star-shaped. One or more slits 524 may have a first slit size 516 that may be designed so that when a target pressure difference is achieved from the upstream side 528a to the downstream side 528b, an expected liquid 526 will be dispensed from the opening 514. The first slit size 516 may further control the flow rate of the liquid 526.

[0137] like Figure 5B As shown, when in the open configuration, the opening 514 can open outwardly along the elastic flow control valve axis 512 (toward the direction of the flow of the liquid 526). The liquid flow rate of the elastic portion 504 can be controlled based on the opening area formed by the one or more slits 524. The opening area can be partially defined by the second slit size 508 and the first slit size 516. In at least one embodiment, the second slit size 508 is defined along the elastic flow control valve axis 512, and the second slit size 508 is defined in a plane orthogonal to the elastic flow control valve axis 512.

[0138] Figure 6 A flow chart illustrating a method 600 of retrofitting a spray gun system to include a flexible flow control valve. Various aspects of the method 600 may be discussed with reference to the figures herein. The method 600 may begin in block 602.

[0139] In block 602, a user may receive a spray gun system to be modified. In at least one embodiment, the spray gun system may include a spray gun platform, such as Figure 1 , Figure 2 and Figure 3 The spray gun system may include a spray gun platform including a liquid inlet, a secondary opening, and a liquid outlet forming a liquid passage therebetween.

[0140] In block 604, the user may remove the nozzle assembly from the spray gun platform before sealing the secondary opening. For example, the attachment structure on the nozzle assembly may be as shown in FIG. Figure 1 It may be screwed on as shown, or may be retained by a retaining ring, protrusions, clips, channels, or a combination thereof.

[0141] In block 606, the user may remove the conventional needle from the needle passage of the spray gun platform and / or nozzle assembly. For example, an adjustment knob may be removed to remove a biasing mechanism (such as those used for a poppet valve or conventional needle).

[0142] In at least one embodiment, block 606 may be optional. For example, if the elastomeric flow control valve is mounted adjacent to the liquid passage (e.g., mounted on the cap, on the hose, or over the liquid outlet), then the needle need not be removed. Thus, the benefits of having an elastomeric flow control valve in the cap may be obtained without the need to provide parts for converting the spray gun system to not use a conventional needle.

[0143] In block 608, a user or third party may seal a secondary opening of a needle passage formed in a spray gun system including a spray gun platform and a nozzle assembly. For example, a user may seal the needle passage by installing a sealing structure that fluidly separates a wettable needle chamber from a non-wettable needle chamber.

[0144] Examples of alternative or improved nozzle assemblies are described in greater detail herein. For example, Fig.11 , Fig. 12A , Fig. 12B and Fig.13 A nozzle assembly is illustrated that is removably connectable to a spray gun platform such as Figure 3 In another example, Fig.14A , Fig. 14B , Fig.15A , Fig. 15B A nozzle assembly having a nozzle assembly body that can be removably coupled to a spray gun platform, such as Figure 1 Spray gun platform.

[0145] In at least one embodiment, sealing can be performed separately from the user. For example, a third party can provide a modified needle assembly for use with the spray gun system. Embodiments of block 608 may be described in greater detail herein.

[0146] In at least one embodiment, block 608 does not include using a conventional needle to perform the seal. For example, an existing packing seal already present in the spray gun platform or nozzle assembly can be used to seal the secondary opening of the needle passage, and the user can remove the conventional needle in block 606 and install the improved needle assembly in block 610.

[0147] Turning to the example, Fig.16 and Fig.17 Examples of improved needle assemblies that may be used in the present disclosure and are further described herein are illustrated. The improved needle assembly may be configured so that it does not form a needle-nozzle seal with a spray gun system. For example, the length dimension of the improved needle assembly may be smaller than a compatible conventional needle so that a needle-nozzle seal is not formed, but the shaft of the improved needle assembly may be able to slide with a packing seal and form a seal with the packing seal. In at least one embodiment, when installed, the first end of the improved needle assembly is at least 0.5 mm away from the elastic flow control valve, or in some embodiments, the size of the elastic flow control valve. In at least one embodiment, installing the improved needle assembly may also include: modifying a conventional needle of the spray gun system so that the needle is no longer able to form a needle-nozzle seal near a liquid outlet. For example, a user may cut off a portion of the needle to allow sealing with an existing packing seal and avoid forming a needle-nozzle seal when the spray gun system is in a first mode.

[0148] In block 612, the user may optionally install a modified poppet valve into the non-wettable needle chamber. For example, the modified poppet valve may be configured to (1) not allow the needle to pass through, (2) slidably seal the non-wettable needle chamber, and (3) engage with the trigger of the spray gun platform. The modified poppet valve may be configured to not have a through hole and to not work with the needle. Thus, in some embodiments, blocks 612 and 610 may be mutually exclusive.

[0149] In block 614, a user or third party may install a resilient flow control valve within a portion of a liquid passage formed in the spray gun system. Installation of the resilient flow control valve may occur such that liquid can be contained by the resilient flow control valve without leaking through the liquid outlet, nozzle liquid outlet, slit, and / or secondary opening. In at least one embodiment, leakage may be determined when the spray gun system is stationary (meaning no gas is flowing through the spray gun system) and / or in a first mode. In at least one embodiment, the resilient flow control valve may form a fluid-tight seal within the liquid passage to be sealingly engaged (i.e., with a sealing surface of the resilient flow control valve). The liquid passage and the needle passage are fluidly coupled.

[0150] In block 616, the user may install the valved nozzle assembly onto the spray gun platform. The nozzle assembly may include a nozzle assembly body or a nozzle barrel. The valved nozzle assembly may be assembled and / or connected similarly to the original nozzle assembly of the spray gun system.

[0151] Once the elastomeric flow control valve is installed in block 616 and when the nozzle assembly is assembled with the spray gun platform and operating in the first mode, the differential pressure across the elastomeric flow control valve is less than the opening pressure of the elastomeric flow control valve and results in a closed configuration. In the second mode, gas flow from the spray gun system including the spray gun platform and the nozzle assembly causes the differential pressure across the elastomeric flow control valve to be at least the opening pressure of the elastomeric flow control valve and thereby causes the elastomeric flow control valve to change to the open configuration.

[0152] In at least one embodiment, method 600 may further include attaching pressurized air to the gas inlet of the spray gun system (once assembled). Liquid through the liquid outlet may be stopped by the elastic flow control valve in response to pressurized air rather than operation of the needle valve.

[0153] Regarding box 608, Figure 7 In the figure, it is shown that Figure 1 1. After the conventional needle is removed, the sealing structure 702 can be used to seal the non-wettable needle chamber 158 from the wettable needle chamber 156, or to form the wettable needle chamber 156 from the needle passage 160. For example, the sealing structure 702 can be pushed axially along the needle / spray axis 124 through the non-wettable needle chamber 158 and can block / seal the secondary opening 154 in a fluid-tight manner.

[0154] Figure 8 , Fig. 9 and Fig.10 This example shows how to use Figure 3 An implementation scheme of a lift valve (not shown) in.

[0155] exist Figure 8 In FIG. 8 , the spray gun system 800 in an assembled state has a spray gun platform 802 , a nozzle assembly 804 , and an air cap 826 .

[0156] The spray gun platform 802 is shown having a liquid passage 816 and a wettable needle chamber 818 formed therein. In at least one embodiment, a portion of the liquid passage 816 (but not the entire liquid passage 816) is coaxial with the wettable needle chamber 818. For example, a portion of the liquid passage 816 that is not coaxial with the wettable needle chamber 818 can direct liquid into the wettable needle chamber 818.

[0157] The liquid passage 816 can lead to a liquid outlet 822 in the nozzle assembly 804. In at least one embodiment, the secondary opening 828 can lead to a wettable needle chamber 818. Instead of a packing seal at the secondary opening 828, the wall 814 can be formed over the secondary opening 828. Thus, in block 608, the wettable needle chamber 818 can be completely sealed. In at least one embodiment, the wall 814 can be angled (non-perpendicular) relative to the wettable needle chamber 818 to facilitate liquid flow from the liquid passage 816.

[0158] exist Figure 6 In block 614 of the embodiment, the user can install the elastomeric flow control valve 808 in the nozzle liquid passage 812. For example, the elastomeric flow control valve 808 can be installed against the nozzle sealing surface 824. In at least one embodiment, an attachment structure 810 can be formed on the nozzle sealing surface 824 to retain the elastomeric flow control valve 808 and form a fluid-tight seal therewith. For example, the attachment structure 810 can be a groove molded into the nozzle liquid passage 812. The groove is shown as an annular groove adjacent to the nozzle sealing surface 824 of the nozzle assembly 804.

[0159] The elastic flow control valve 808 may have a frame structure 820 to provide a flexible portion (at Figure 5A and Figure 5B 822) and enables the attachment structure 810 to mate with the complementary attachment structure 806 on the nozzle assembly 804. The frame structure 820 may have a complementary attachment structure 806 that mates with the attachment structure 810. When the differential pressure across the elastic flow control valve 808 exceeds the opening pressure, the nozzle assembly 804 can discharge liquid through the liquid outlet 822. This can be done, for example, by applying a negative pressure around the liquid outlet 822 (e.g., by flowing a gas around the liquid outlet 822).

[0160] exist Fig. 9 , the spray gun system 900 can be similar to the spray gun system 800, except that in block 608, a sealing structure 902 is inserted through a secondary opening 910 leading to the wettable needle chamber 818. The sealing structure 902 can be compressible after being inserted into the secondary opening 910 and expand to form a liquid-tight seal when in place.

[0161] The sealing structure 902 may also have a stepped portion 904 configured to be sized according to the radial dimension of the secondary opening 910 of the spray gun platform. In at least one embodiment, the sealing structure 902 may be a plug having a stepped portion 904 and a retaining structure 906 configured such that the sealing structure 902 is restricted from extending beyond the dimension 908. The sealing structure 902 may have a distal end 912 abutting the liquid passage 816. In at least one embodiment, the user may insert the sealing structure 902 into the secondary opening 828 and at least partially into the wettable needle chamber 818. The sealing structure 902 may be configured to be attached to the body of the spray gun platform 914 (or nozzle barrel) and fill the secondary opening 910.

[0162] The wettable needle chamber 818 can have a dimension 908 that branches off from the liquid passage 816. In at least one embodiment, the sealing structure 902 can be configured to fill a majority of the dimension 908.

[0163] Fig.10 A spray gun system 1000 is illustrated that is similar to the spray gun system 900 , except that the seal structure 902 is optional and functions as a dust cap, and the second fluid pathway includes a liner 1002 that fluidly isolates the liquid from the wettable needle chamber 818 .

[0164] The spray gun system 1000 may include Fig. 9 804. The spray gun system 1000 may also include a liner assembly 1004 that may serve as a fluid path that delivers liquid from a liner liquid inlet 1012 through the elastomeric flow control valve 808 and out through the liquid outlet 822. In block 608, the secondary opening 910 may be sealed by inserting a sealing structure 1010, which may be shorter than the sealing structure 902. For example, the sealing structure 1010 does not fill a majority of the wettable needle chamber 818.

[0165] The liner assembly 1004 may include a liner liquid inlet 1012 at one end that may receive liquid from a liquid reservoir system and a distal end 1008 at an opposite end that may be coupled to the elastomeric flow control valve 808. The liner assembly 1004 may have a liner tube 1002 that connects the liner liquid inlet 1012 to the distal end 1008 such that any liquid from the liner liquid inlet 1012 is conveyed through the liner tube 1002 and may be contained by the liner tube 1002. The liner tube 1002 may be flexible so that the distal end 1008 can meander through the liquid passage 816 and into the nozzle assembly 804. The liner tube 1002 may also have a length dimension sufficient to allow the distal end 1008 or the elastomeric flow control valve 808 to abut the nozzle sealing surface 824 of the nozzle assembly 804.

[0166] In at least one embodiment, the liner 1002 is self-contained and fluidly coupled to a liquid reservoir system. In at least one embodiment, the liner and liquid reservoir system can be integral and can contain a liquid that is pre-filled, which will result in the liquid being completely contained in a closed system.

[0167] In at least one embodiment, sealing the secondary opening 910 can also include inserting the liner assembly 1004 into the liquid inlet 1006, through a portion of the liquid passage 816 and toward the liquid outlet 822. The insertion can be performed by a user installing (e.g., by snaking) the distal end 1008 of the liner assembly 1004 through the liquid passage 816. In at least one embodiment, the liner 1002 is configured to pass through and conform to portions of: (1) the liquid passage 816 of the spray gun platform 802, and / or (2) the nozzle liquid passage 812 of the nozzle assembly 804.

[0168] In at least one embodiment, the distal end 1008 of the liner 1002 has a resilient flow control valve 808 mounted thereon. In at least one embodiment, the frame structure 820 can be integrally formed with the distal end 1008.

[0169] In at least one embodiment, the elastomeric flow control valve 808 or the distal end 1008 can have sealing features that facilitate the elastomeric flow control valve 808 to maintain a fluid-tight seal against the distal end 1008. Examples of sealing features include diametric interference (press fit), clamping members, adhesives, magnetic members, or elastomeric members such as o-rings. Thus, liquid from the liner liquid inlet 1012 can only exit the spray gun system 1000 at the elastomeric flow control valve 808. In at least one embodiment, the liner assembly 1004 is configured to receive liquid from the liner liquid inlet 1012 through the distal end 1008 of the liner 1002.

[0170] Fig.11 A valved nozzle assembly 1100 is illustrated in a nozzle cartridge. The valved nozzle assembly 1100 may be modified from a nozzle cartridge commercially available for a high performance spray gun from 3M (Saint Paul, MN). For example, the valved nozzle assembly 1100 may include an air cap 1108 and a nozzle assembly body 1102. In at least one embodiment, blocks 608 and 614 of method 600 may be performed at a third party facility so that the resulting valved nozzle assembly 1100 is easily installed by a user in block 616.

[0171] The nozzle assembly body 1102 may optionally be formed from multiple parts, including a barrel body 1104 and a liquid nozzle portion 1106. An elastic flow control valve 1112 may be sandwiched between the barrel body 1104 and the liquid nozzle portion 1106 in the valved nozzle assembly 1100.

[0172] The nozzle assembly body 1102 may have a first end 1150 and a second end 1152. The second end 1152 is configured to be attached to a Figure 3 For example, the non-wettable needle chamber 1142 can be coupled to the needle chamber 304, and the nozzle gas passage in the valved nozzle assembly 1100 can be coupled to Figure 3 The gas passage in the spray gun platform 300.

[0173] The nozzle assembly body 1102 may include a liquid inlet 1122 and a liquid outlet 1126. A nozzle liquid passage 1124 is formed between the liquid inlet 1122 and the liquid outlet 1126. The nozzle assembly body 1102 may include a needle passage 1140 formed therein. The needle passage 1140 may initially be designed to receive a packing seal that divides the needle passage 1140 into a wettable needle chamber 1144 and a non-wettable needle chamber 1142. The needle passage 1140 may be coaxial with the spray axis 1120. In at least one embodiment, the wettable needle chamber 1144 is formed by a portion of the nozzle liquid passage 1124 (e.g., a portion between the nozzle liquid outlet 1126 and the secondary opening 1148 / packing seal (not shown)). The needle passage 1140 may intersect the nozzle liquid passage 1124 near the secondary opening 1148.

[0174] In block 608, the user or third party may seal the secondary opening 1148 within the valved nozzle assembly 1100. The sealing structure 1130 may be positioned between the end of the liquid chamber 1128 and the tube end 1132. In at least one embodiment, the tube end 1132 may form the secondary opening 1148. In at least one embodiment, the sealing structure 1130 may be installed near or at the original location of the packing seal (which would have been removed to install the sealing structure 1130).

[0175] In at least one embodiment, the sealing structure 1130 can be integrally molded with the barrel body 1104. For example, the non-wettable needle chamber 1142 can be completely filled and no passage can be formed. Therefore, a third party can provide a sealed nozzle assembly to a user. In at least one embodiment, the sealing structure 1130 can separate the non-wettable needle chamber 1142 from the wettable needle chamber 1144 fluidly.

[0176] In block 614, a user or third party may install an elastic flow control valve within the nozzle liquid passage 1124 or liquid passage. The elastic flow control valve may be installed between the barrel body 1104 and the liquid nozzle portion 1106. Both the barrel body 1104 and the liquid nozzle portion 1106 may include features that allow for a fluid tight connection.

[0177] At the first end 1150, the barrel body 1104 includes a wall 1118 and a wall 1116 that are configured to mate with the liquid nozzle portion 1106. The liquid nozzle portion 1106 may have a groove 1136 fixedly coupled to the wall 1118 and an attachment point 1138 fixedly coupled to the wall 1116 so as to form a fluid-tight seal. The liquid nozzle portion 1106 may also have an edge portion 1146 that defines a nozzle sealing surface 1110 of the nozzle liquid passage 1124. A shaping gas passage may be established between the wall 1118 and the wall 1116.

[0178] The tube end 1134 can be configured to abut the elastomeric flow control valve 1112 (including the flange 1114). The elastomeric flow control valve 1112 can be configured to be positioned between the tube end 1134 and the rim portion 1146. In at least one embodiment, the flange 1114 of the elastomeric flow control valve 1112 can abut the rim portion 1146.

[0179] Once installed, the valved nozzle assembly 1100 may be a valved nozzle assembly or a valved nozzle cartridge that may be mounted on a spray gun platform, as described in block 616 .

[0180] Fig. 12A and Fig. 12B A nozzle barrel 1200 that can be used with a spray gun platform is illustrated. The nozzle barrel 1200 can be similar in construction to the nozzle barrel described in U.S. Patent Application No. 20110024524 by Fox, except that one end formed to a needle chamber is sealed. For example, the nozzle barrel 1200 can have a nozzle barrel body 1204 that is compatible with a complementary spray gun platform. The nozzle barrel body 1204 can have at least two openings formed therein: a liquid outlet 1216 and a liquid inlet 1226. For example, the liquid outlet 1216 can be a place where fluid is discharged from the nozzle barrel body 1204, and the liquid inlet 1226 can be an inlet where the nozzle body 1204 receives fluid from a source. In operation, air can flow around the outer surface 1202 of the nozzle barrel body 1204, and liquid can flow on the inner surface 1222.

[0181] The liquid inlet 1226 can be fluidly connected to the liquid outlet 1216 via a liquid passage 1208 formed therein. The liquid passage 1208 can include various chambers, such as a liquid chamber 1210, a secondary opening 1212, and a wettable needle chamber 1230. Liquid can flow from the liquid chamber 1210 into the wettable needle chamber 1230, through the elastomeric flow control valve 1218, the nozzle sealing surface 1224, and then through the liquid outlet 1216.

[0182] In block 614, an elastic flow control valve 1218 can be installed in the liquid passage 1208 and actuated in response to negative pressure from the gas flow on the outer surface 1202. In at least one embodiment, the elastic flow control valve 1218 can include a frame structure 1220 that can be attached to the inner surface 1222.

[0183] In block 608, the sealing structure 1206 is mounted on the tube end 1228 of the nozzle cartridge body 1204. For example, the sealing structure 1206 is shown as a separate part, but can also be integrally molded with the tube end 1228 to form a wall (similar to Figure 8 ). In at least one embodiment, the secondary opening 1212 is outside of the confluence area 1214 of the nozzle barrel 1200. In at least one embodiment, the sealing structure 1206 can abut a portion of the liquid chamber 1210 such that the secondary opening 1212 is not present.

[0184] Fig.13 A nozzle barrel 1300 is illustrated that is similar to nozzle barrel 1200 , except that nozzle barrel 1300 may have a radial flange 1314 having an opening 1308 formed therein.

[0185] For example, the nozzle barrel 1300 may have a first end 1318 for engaging with the gas cap and a second end 1316 opposite the first end 1318 for engaging with the spray gun platform 102. The second end 1316 may have a spur protrusion 1312 for fitting into a specific geometry of the spray gun platform. A radial protrusion 1314 may be disposed toward the first end 1318. The nozzle barrel 1300 may have a liquid passage 1320 formed within the body of the nozzle barrel 1300 and a gas passage 1306 formed on the outer surface of the nozzle barrel 1300. In at least one embodiment, the gas may travel across the outer surface and through the opening 1308.

[0186] The liquid passage 1320 can have a liquid chamber 1304 that receives liquid from a liquid source. The liquid chamber 1304 leads to a needle passage 1322. A secondary opening 1324 can lead to the needle passage 1322. In at least one embodiment, the needle passage 1322 of the nozzle barrel 1300 can include a sealing structure 1302 to seal the secondary opening 1324 when installed in a spray gun system in block 608.

[0187] In at least one embodiment, the elastomeric flow control valve 1310 can be installed in the liquid passage 1320 (e.g., between the liquid chamber 1304 and the needle passage 1322) in frame 614. The gas flow can generate a negative pressure at the fluid tip (not shown) and cause the liquid to be dispensed through the liquid outlet of the body of the nozzle assembly (not shown).

[0188] Fig.14A and Fig. 14B The nozzle assembly 1400 is illustrated. The nozzle assembly 1400 may be Figure 1 For example, although the nozzle assembly 1400 may have a nozzle liquid inlet 1410 and an attachment structure 1402 for coupling with a liquid passage of a corresponding spray gun platform, the nozzle assembly 1400 may have an internal nozzle passage formed therein.

[0189] For example, the nozzle assembly 1400 may have a nozzle liquid passage 1406 formed between a nozzle liquid inlet 1410 and a liquid outlet 1408 coaxial with the spray axis 1420 (and the needle passage 1412). The nozzle liquid passage 1406 may fluidly couple the liquid outlet 1408 with the nozzle liquid inlet 1410. The nozzle liquid passage 1406 may be aligned with the needle passage 1412. The nozzle gas passage 1404 may be formed through the wall of the nozzle assembly 1400 so that a flow from a gas may be delivered around a portion of the nozzle assembly 1400 and directed through the nozzle gas passage 1404 (shown as being formed by a plurality of holes formed in the nozzle assembly 1400).

[0190] Fig. 14B An internal cross section of the nozzle assembly 1400 is illustrated. For example, the elastomeric flow control valve 1414 can be placed within the nozzle liquid passage 1406, but the elastomeric flow control valve 1414 can be installed in a position upstream of the nozzle sealing surface 1424 (which is adjacent to the liquid outlet 1408) in the frame 614. The elastomeric flow control valve 1414 can have a slit 1422 formed therein. The slit 1422 can intersect the spray axis 1420 and can be opened as described herein.

[0191] The elastic flow control valve 1414 may have an attachment structure 1416 for securing the elastic flow control valve 1414 against the needle passage 1412. The attachment structure 1416 may be a flange, a lip, a protrusion, or a detent. The attachment structure 1416 is shown as an annular flange and may form a sealing surface 1428 to sealably engage with a portion of the needle passage 1412. The needle passage 1412 may have a complementary attachment structure 1418 that is configured to mate with the attachment structure 1416 to form a secure mechanical connection between the elastic flow control valve 1414 and the needle passage 1412. In at least one embodiment, the elastic flow control valve 1414 may be further secured to the needle passage 1412 using an adhesive, ultrasonic welding, overmolding, or other attachment mechanisms. In at least one embodiment, the edges of the attachment structure 1416 and / or the complementary attachment structure 1418 may have an adhesive disposed therein. In at least one embodiment, the elastomeric flow control valve 1414 can divide the needle passage 1412 into a nozzle sealing surface 1424 (which can be tapered) and a chamber 1426 .

[0192] Fig.15A and Fig. 15B Another embodiment of a valved fluid nozzle 1500 is illustrated. In at least one embodiment, a kit including a spray gun nozzle body 1504, an elastic flow control valve 1502, and / or a sealing structure (not shown) can be formed. In at least one embodiment, the elastic flow control valve 1502 can be inserted into the spray gun nozzle body 1504 of the spray gun, as described in block 614. Examples of the elastic flow control valve 1502 can include single-way valves and two-way valves, duckbill valves, cross valves, etc. The elastic flow control valve 1502 shown is a duckbill valve having a single horizontal slit 1508 and a flange 1506.

[0193] The flange 1506 can be annular and have a flange diameter that is different from the inner diameter of the elastomeric flow control valve 1502. The spray gun nozzle body 1504 can have a fluid opening (for a second fluid passage to the liquid). The spray gun nozzle body 1504 can have a rim 1512 formed by the wall of the spray gun nozzle body 1504. The rim 1512 can have a rim diameter. In at least one embodiment, the secondary seal 1510 can be nested within the rim diameter to provide a better fit of the elastomeric flow control valve 1502. The frame can have a frame diameter that receives the flange 1506. In at least one embodiment, the flange diameter is larger than the frame diameter.

[0194] When assembled, the elastomeric flow control valve 1502 can form a fluid-tight seal with the rim 1512 of the elastomeric flow control valve 1502. The flange 1506 can serve as a sealing surface and sealingly engage with the rim 1512.

[0195] Fig.16An improved needle assembly 1600 that can be used in block 610 is illustrated. In at least one embodiment, the improved needle assembly 1600 can be used to replace the needle in the spray gun system 700 when converting the spray gun platform, and can have a sealing structure 1608 mounted thereon. The improved needle assembly 1600 can include a front shaft segment 1610 and a rear shaft segment 1614. The improved needle assembly 1600 can have a first end 1602 and a second end 1604. The first end 1602 can be configured to be oriented toward the fluid nozzle of the spray gun, and the second end 1604 can be oriented opposite to the first end 1602 and configured to be oriented toward the adjustment knob of the spray gun.

[0196] Between the front shaft segment 1610 and the rear shaft segment 1614 may be a needle protrusion 1612 for engaging with a biasing mechanism disposed on the second end 1604. A sealing structure 1608 may be disposed on the first end 1602. The sealing structure 1608 may be spaced a setback distance 1606 from the needle protrusion 1612 and configured to fluidly seal the non-wettable needle chamber from a liquid passageway of the spray gun. The rear shaft segment 1614 and the needle protrusion 1612 may be sized similarly to conventional needles used for modeling and manufacturing of spray gun platforms.

[0197] The sealing structure 1608 can be any structure that allows sealing with the needle chamber. In at least one embodiment, the sealing structure 1608 can be capable of moving in the axial direction with the spray gun system. In at least one embodiment, the sealing structure 1608 can be an expansion seal. The expansion seal can be configured to fit and / or sealably engage the first hole (e.g., secondary opening 154) passing through the needle chamber, and expand to a larger hole size in the wettable needle chamber and form a fluid-tight seal. The expansion seal can maintain a fluid-tight seal while undergoing axial movement. Examples of expansion seals may include umbrella seals, piston seals, plunger seals, or combinations thereof. In at least one embodiment, the sealing structure 1608 may include a packing seal or a poppet seal so that the front shaft segment 1610 can move against it while maintaining a fluid-tight seal.

[0198] Fig.17 An improved needle assembly 1700 is illustrated, which is similar to the improved needle assembly 1600, except that the improved needle assembly 1700 does not include a sealing structure for sealing directly against the wettable needle chamber. For example, the improved needle assembly 1700 can be configured to seal against the inner diameter of the packing seal. Thus, the front shaft segment 1610 can be slidably sealed against the packing seal, and the front shaft segment 1610 and the packing seal both form a sealing structure at the secondary opening.

[0199] First end 1704 may be different from first end 1602 in that there is no sealing structure at first end 1704 (which may change dimension 1702). Improved needle assembly 1700 may have dimension 1702 such that a needle-nozzle seal may not be formed when the trigger is in the unactivated position. For example, if improved needle assembly 1700 is configured to sealingly engage with Figure 3 If the needle assembly 1600 is within the spray gun platform 300, the dimension 1702 may be smaller than the dimension 320. Although shown as having a blunt end, both the improved needle assembly 1600 and the improved needle assembly 1700 may have a sharp needle tip.

[0200] The improved needle assembly 1700 can be configured to work with an existing poppet valve in a spray gun platform. For example, the poppet valve can include a poppet valve inner diameter and a poppet valve outer seal. In at least one embodiment, the improved needle assembly 1700 is configured to form a slidable fluid-tight seal with the poppet valve inner diameter of the poppet valve.

[0201] "Spanning" means between two opposing major surfaces. For example, between the upstream and downstream sides of a flexible flow control valve.

[0202] "Actuator" refers to a device or mechanism configured to manually control a gas valve from outside the gas valve body and / or outside the spray gun body or spray gun component body. The term actuator may also include a button or trigger structure.

[0203] "Atmosphere" refers to the environmental conditions surrounding the spray gun system (barometric pressure, temperature, etc.).

[0204] "Atmospheric pressure" refers to the pressure exerted by the atmosphere on the spray gun system.

[0205] "Subject" refers to the material form of an object.

[0206] "Closed" refers to a state of the elastic flow control valve in which no liquid flows when the liquid is on the upstream side of the elastic flow control valve.

[0207] "Closed configuration" refers to a configuration of the elastomeric flow control valve that does not allow liquid to pass from the upstream side to the downstream side when liquid is present on the upstream side of the elastomeric flow control valve. The closed configuration may include an unopened slit or self-sealing flap in the elastomeric portion.

[0208] "Closing pressure" refers to the pressure at or below which the flexible flow control valve transitions from an open configuration to a closed configuration. The closing pressure and the opening pressure may be different values.

[0209] A "conventional needle" refers to a needle having a needle tip that is configured to form a needle-nozzle seal with a nozzle sealing surface. An adjustment knob or other portion of the spray gun platform may form an end stop for a conventional needle.

[0210] "Differential pressure" refers to the difference in pressure between an upstream (P1) location and a downstream (P2) location. This can be expressed as ΔP = P1 - P2.

[0211] "Downstream liquid chamber" refers to a chamber downstream of the elastomeric flow control valve. The downstream liquid chamber may be configured to facilitate negative fluid pressure in response to positive fluid flow in the gas passageway.

[0212] The "downstream side" refers to the side downstream of the elastic portion.

[0213] "Elastomer" refers to natural or synthetic polymers, such as natural or synthetic rubber, that exhibit viscoelastic behavior under deformation, having a low elastic modulus (eg, no greater than 0.5 GPa) and a high strain to failure.

[0214] "Fluid tight" means preventing the ingress of fluids such as water at the appropriate operating pressure of the spray gun system. In at least one embodiment, the liquid may be at a pressure of no greater than 50 psig.

[0215] "Gas" refers to a substance or thing that is in the state of expanding freely to fill an entire container, having no fixed shape (unlike a solid) and having no fixed volume (unlike a liquid). Gases can be used in a spray process to atomize bulk liquids and form a spray pattern. Gases can be used as carriers for liquids to aid in the delivery of fluids. Examples of gases include nitrogen, carbon dioxide, gas mixtures such as air, and even gas propellants, which may be in a gaseous state under standard state conditions but are liquefied at higher pressures.

[0216] "Gas valve" refers to a device that controls, directs, or regulates the flow of gas (and can indirectly control, direct, or regulate the flow of liquid by changing the differential pressure across the elastomeric flow control valves described herein) in a binary or staged manner. Examples of gas valves may include gate valves, poppet valves, butterfly valves, ball valves, etc.

[0217] "Grip portion" refers to a segment configured to be gripped by a user's hand.

[0218] "Liner" means disposed in or extending along a straight or nearly straight pipeline.

[0219] "Liquid" refers to coating materials that can be applied to a surface using a spray gun system, including (but not limited to) paints, primers, base coats, lacquers, varnishes and paint-like materials, as well as other materials such as adhesives, sealants, fillers, putties, powder coatings, blasting powders, abrasive slurries, mold release agents and casting dressings, which can be applied in atomized or non-atomized form depending on the properties of the material and / or the intended application. In these applications, the term liquid is used generally because it can include solid particles (pigments, powders, granules, etc.) suspended or dissolved in a carrier liquid.

[0220] "Liquid outlet" refers to the location where liquid leaves the spray gun component or will leave the spray gun component without interference from the elastic flow control valve. For example, the elastic flow control valve can be mounted on the liquid outlet of the spray gun component and form part of the liquid outlet. In at least one embodiment, the liquid outlet can be at least partially formed at the distal end of the spray gun component.

[0221] "Liquid passage" refers to the liquid flow path within the body of the spray gun component.

[0222] "Liquid reservoir component" refers to a component within a liquid reservoir system. Examples of liquid reservoir components include caps, containers, cups, pouches, bags, adapters, and liquid hose assemblies.

[0223] A "liquid reservoir system" refers to a system configured to hold or transport a liquid. A liquid reservoir system may include at least one liquid reservoir component. A liquid reservoir system may include multiple liquid reservoir components, such as a cup and a lid. A liquid reservoir system may also include a component fluidly coupled to a barrel, such as a liquid hose assembly. A liquid reservoir system may be a type of liquid source.

[0224] A "manually operated valve" refers to a valve that can be controlled via a mechanical linkage to an actuator. For example, a manually operated valve may be mechanically coupled to another component, such as a trigger of a spray gun platform. The manually operated valve may be translated along the longitudinal axis of the spray. Examples of manually operated valves include poppet valves, globe valves, gate valves, spherical valves, butterfly valves, plug valves, sliding valves, needle valves, levers, or pinch valves. The term "manually operated valve" does not include an elastic flow control valve. For example, even if a slit in the elastic portion can be pushed with manual pressure, an elastic flow control valve is not a "manually operated valve" because the primary and / or intended mechanism is based on differential pressure rather than manual activity.

[0225] "Mixing zone" refers to where the gas stream exits the gas outlet and combines, interacts, intersects and / or atomizes the liquid stream from the liquid outlet.

[0226] "Needle chamber" refers to a wettable needle chamber, a non-wettable needle chamber, or a discrete portion of a needle passageway.

[0227] "Needle passage" refers to a passage formed within a spray gun system (including a nozzle assembly and a spray gun platform) that is configured to receive a conventional needle and associated components such as a biasing mechanism. At a first end, the needle passage may include a nozzle sealing surface. At a second end, the needle passage may include an opening that may be sealed by an adjustable knob.

[0228] "Nozzle assembly" refers to a fluid nozzle and a device for coupling the fluid nozzle to a spray gun platform. The nozzle assembly is used to deliver gas through a gas passage formed therein and / or deliver liquid through a liquid passage formed therein. The gas passage and / or liquid passage of the nozzle assembly can be paired with the gas passage and / or liquid passage of the spray gun platform. In at least one embodiment, the nozzle assembly can include a nozzle barrel.

[0229] "Nozzle cartridge" refers to a spray gun component having a liquid passage for direct connection to a liquid source / liquid reservoir system and a liquid outlet. When combined with a spray gun platform, the spray gun platform itself does not include a liquid passage, but the spray gun platform may include a portion of a gas passage for connection to a gas source. A nozzle cartridge may refer to a type of nozzle assembly.

[0230] "Open" refers to any state that allows some liquid to flow across the flexible flow control valve when liquid is present on the upstream side. For example, open may refer to partially open.

[0231] "Open configuration" refers to a configuration that allows liquid to pass from the upstream side to the downstream side when liquid is present on the upstream side.

[0232] "Opening size" refers to the maximum size of the opening of the elastic flow control valve.

[0233] "Opening pressure" refers to the differential pressure that can open the elastic part of the elastic flow control valve. Opening pressure is synonymous with cracking pressure.

[0234] "Elasticity" refers to the ability of a material to absorb energy when elastically deformed and release that energy when unloaded. Upon unloading, the material will return to its original state. Elastomeric materials can be elastic.

[0235] "Resilient flow control valve" refers to a valve operable to control the flow of a fluid, the valve having the ability to adjust its degree of opening based on changes in differential pressure, and the resiliency to remain in a normally closed configuration once a predetermined closing differential pressure is reached. The term "resilient flow control valve" may be used to refer to a resilient portion, or any component of a resilient flow control valve.

[0236] "Elastic portion" refers to the portion of an elastic flow control valve that controls fluid flow. The elastic portion is configured to change between an open configuration and a closed configuration based on a differential pressure across the elastic portion relative to an opening pressure of the elastic portion. The elastic portion can be elastomeric, but a rigid or semi-rigid layer can also be utilized.

[0237] "Rigid" is used to refer to materials that do not deform / flex easily. In one example, a rigid material can be described as having a "stiffness" or elastic modulus of at least 0.5 GPa.

[0238] "Sealing structure" refers to an element or structure that seals off the needle chamber (e.g., wettable or non-wettable) or other parts of the spray gun from the environment. The sealing structure can be liquid-tight so that liquid does not flow into or out of the needle chamber. The sealing structure can include a plug, a stopper, a wall, a weld, an injection molded part, etc.

[0239] "Sealingly engaged" means that a surface of a first body (ie, a sealing surface) forms a fluid-tight seal with a surface of a second body, either directly or indirectly (eg, via another structure, like a packing seal or a frame structure).

[0240] If the first body is a resilient flow control valve having a sealing surface and the second body is a nozzle liquid passage having an internal bore surface, the sealing surface of the resilient flow control valve may form a fluid tight seal with the internal bore of the nozzle liquid passage.

[0241] The term "sealingly engaged" may refer to a sealing surface on the periphery of the first body or the second body, rather than the first body or the second body as a whole being fluid-tight. For example, an elastic flow control valve may have a slit or opening that may open in response to a differential pressure, but is not fluid-tight in some cases.

[0242] "Spray equipment" refers to any equipment or components used to transport, store, or atomize bulk fluids into a fine spray or mist of droplets. Spray equipment can refer to devices that use air spray, airless, rotary / centrifugal, ultrasonic, or electrostatic methods.

[0243] "Spray gun" refers to a type of spray equipment. A spray gun may refer to an air spray gun, which uses a low-pressure stream of liquid mixed with compressed gas to atomize a liquid in a controlled manner.

[0244] "Spray gun components" refers to components that form part of a spray gun system. Examples of spray gun components include spray gun platforms, valves, nozzle assemblies, nozzle barrels, gas caps, liquid reservoir systems and liquid reservoir components thereof. Spray gun components may also include any device that is physically attached to any of the aforementioned spray gun components.

[0245] "Spray gun platform" refers to the spray gun component having a gripping portion, an actuator, and connections to a gas source and optionally a liquid reservoir system. In at least one embodiment, a spray gun platform can refer to a spray gun body with an integrated liquid inlet. In at least one embodiment, a spray gun platform can be manually coupled to a nozzle barrel or nozzle assembly.

[0246] "Spray gun system" refers to one or more spray gun components that, when assembled together, are configured to atomize and / or shape a liquid into a spray. A spray gun system may use air to atomize a liquid. A spray gun may be a manual spray gun system or may be a robotic spray gun system (meaning attached to a robotic arm).

[0247] "Tapered region" refers to a region that tapers from a first dimension to a second dimension. The second dimension is smaller than the first dimension. A dimension may include a diameter or a circumference, and may generally indicate a hole or opening size.

[0248] "Tubular" refers to a long, round and hollow shape. Tubular can refer to an elliptical or polygonal cross section.

[0249] The "upstream side" refers to the side upstream of the elastic portion.

Claims

1. An improved needle assembly, the improved needle assembly comprising: a first shaft segment having a first end, wherein the first end is configured to be oriented toward a nozzle sealing surface of a spray gun system; a second shaft segment having a second end opposite the first end, wherein the second shaft segment is configured to sealingly engage in a non-wettable needle chamber of the spray gun system; wherein the second end is configured to operably engage a component of the spray gun system and the first end is configured to not contact the nozzle sealing surface to form a needle-nozzle seal; and The improved needle assembly has a needle length dimension that is less than a length dimension of a needle passageway of the spray gun system.

2. The improved needle assembly of claim 1, wherein the first shaft segment has a length dimension that is smaller than a conventional needle for use with the spray gun system, wherein the first end is configured not to form a fluid-tight seal with the spray gun system.

3. The improved needle assembly of claim 1, wherein the second shaft segment is configured to form a slidable fluid-tight seal with a packing seal.

4. The improved needle assembly of claim 1 , wherein the first shaft segment is configured to form a fluid-tight seal with a poppet valve that seals the non-wettable needle chamber and engages with a trigger of the spray gun system, wherein the poppet valve includes a through passage from a poppet valve flange end to a poppet valve distal end.

5. The improved needle assembly according to claim 1, further comprising: A sealing structure is disposed on the first end of the first shaft segment, wherein the sealing structure is configured to form a fluid-tight seal with a portion of the needle passage to separate the needle passage into a wettable needle chamber and the non-wettable needle chamber.

6. The improved needle assembly of claim 5, wherein the second shaft segment is configured to engage a biasing mechanism.

7. A kit, comprising: A resilient flow control valve configured to sealingly engage within or directly adjacent a portion of a nozzle liquid passageway of a nozzle assembly, the nozzle assembly comprising: a nozzle gas inlet and a nozzle gas outlet, wherein an atomizing gas passage is formed between the nozzle gas inlet and the nozzle gas outlet; and a nozzle liquid inlet and a nozzle liquid outlet, wherein the nozzle liquid inlet and the nozzle liquid outlet form the nozzle liquid passage; wherein the atomizing gas passage is configured to be removably coupled to a gas passage of a spray gun platform, The nozzle liquid passage is configured to form a fluid-tight seal with a needle of the spray gun platform at a needle-nozzle seal of the nozzle assembly.

8. The kit of claim 7, wherein the nozzle assembly includes an attachment structure on an exterior surface configured to mate with a compatible attachment structure on the spray gun platform.

9. The kit of claim 8 or claim 8, further comprising: The spray gun platform, wherein a spray gun system includes the spray gun platform and the nozzle assembly, wherein the spray gun system includes a needle passage configured to allow a conventional needle to pass through both the spray gun platform and the nozzle assembly, wherein the portion of the nozzle liquid passage is coaxial with the needle passage.

10. The kit of claim 9, wherein the nozzle liquid passage is configured to be removably coupled to a liquid passage of the spray gun platform at a second end opposite the needle-nozzle seal.

11. The kit of any one of claims 7 to 10, wherein when the nozzle assembly is assembled with the spray gun platform and operating in a first mode, a differential pressure across the elastomeric flow control valve is less than an opening pressure of the elastomeric flow control valve and results in a closed configuration; Wherein in the second mode, gas flow from the spray gun system including the spray gun platform and the nozzle assembly causes the differential pressure across the elastic flow control valve to be at least the opening pressure of the elastic flow control valve, and thereby causes the elastic flow control valve to change to an open configuration.

12. The kit of claim 11, wherein the resilient flow control valve includes a slit configured to form an opening in the open configuration.

13. A kit according to any one of claims 7 to 12, wherein the nozzle assembly is a nozzle barrel, wherein the nozzle liquid passage is formed between the nozzle liquid inlet and the nozzle liquid outlet, and a wettable needle chamber is formed by a portion of the nozzle liquid passage located between the nozzle liquid outlet and a secondary opening of the spray gun system.

14. The kit according to any one of claims 7 to 13, further comprising: a poppet valve configured to: (1) not permit passage of the needle, (2) slidably seal the non-wettable needle chamber, and (3) engage a trigger of the spray gun platform; The spray gun platform includes the non-wettable needle chamber formed therein.

15. The kit according to any one of claims 7 to 15, further comprising: An improved needle assembly according to any one of claims 1 to 6.

16. A method comprising: An elastomeric flow control valve is mounted within a portion of a liquid passage formed in a spray gun system such that liquid can be contained by the elastomeric flow control valve without liquid leaking from a liquid outlet of the spray gun system, wherein a wettable needle chamber is coaxial with the portion of the liquid passage.

17. The method according to claim 16, further comprising: A secondary opening formed in the spray gun system including a spray gun platform and a nozzle assembly is sealed to seal a needle passage, wherein the needle passage is configured to allow a conventional needle to pass through both the spray gun platform and the nozzle assembly, wherein the seal forms the wettable needle chamber and the non-wettable needle chamber from the needle passage, wherein sealing the secondary opening does not use the conventional needle, and wherein as a result of the seal, no leakage occurs through the secondary opening.

18. The method according to claim 16 or 17, further comprising: A conventional needle is removed from the needle passage including the wettable needle chamber.

19. The method according to any one of claims 16 to 18, further comprising: An improved needle assembly according to any one of claims 1 to 6 is installed.

20. The method of claim 19, wherein the modified needle assembly does not form a needle-nozzle seal with the spray gun system, wherein when installed, the first end of the modified needle assembly is at least 0.5 mm away from the elastomeric flow control valve, or the size of the elastomeric flow control valve.

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